Part 1

WM 1001Z1 Disassembling engine - Turbo

Tools

















Technical values






Information

Loosen or tighten all threaded connections according to instructions in the document -> 1X00IN Tightening torques for engine MA170 and MA170 S.

Overview of special tools





Special tools for engine disassembly






Preliminary work

NOTICE

Dirt and contamination

- Risk of damage to units or components

-> Protect components from dirt and contamination.
-> Clean or replace dirty components.

WARNING

Highly inflammable or explosive materials

- Danger of fire or explosion

-> Avoid contact with hot parts or sources of ignition.
-> Use suction to remove ignitable vapours.
-> Attach warning sign in a clearly visible position.

Information

- All engine repairs must be carried out using only the specified tools.

- Only these tools have been tested and approved.

Information

- Photos taken with a digital camera are helpful for dealing with complicated line routing (engine wire harness).

- -> 975219 Removing and installing wire harness for engine .

Information

Specifications for wrench sizes (a/f specifications) for screw heads are described as follows:

- Torx screws: (E.) for external Torx, (T.) for internal Torx.

- Hexagon-head bolts (internal and external hexagon): Wrench size (a/f)

1. Remove the engine.
-> 100119 Removing and installing engine 100119 Removing and installing engine.
2. Remove the transmission.
-> 34352750 Removing and mounting transmission 34352750 Removing and mounting transmission.
-> 373427 Removing and mounting Porsche Double Clutch (PDK) 373427 Removing and mounting Porsche Doppelkupplung (PDK).
3. Remove the flywheel.
-> 136019 Removing and installing flywheel - PDK transmission - Turbo 136019 Removing and installing flywheel.
-> 136019 Removing and installing dual-mass flywheel - Turbo 136019 Removing And Installing Dual-mass Flywheel - Turbo.
4. Mount the engine on the engine assembly support.
-> 1001IN Tools for removing units and working on the engine assembly support Tools and Equipment.
5. Remove rear silencer.
-> 263319 Removing and installing rear silencer - Turbo Service and Repair.
Get another person to help you carry out the work!
5.1. Unclip oxygen sensor cable -arrows-.





Releasing oxygen sensor cable





5.2. Remove the four M8 hexagon nuts (a/f 13) on the turbocharger flange and replace the nuts.
5.3. Unscrew one external Torx screw (E10, M6 x 12) on the turbocharger heat shield.
5.4. Remove rear silencer.
6. Remove engine carrier -1-.
-> 103019 Removing and installing engine carrier - Turbo 103019 Removing And Installing Engine Carrier - Turbo.
6.1. Unclip exhaust temperature sensor line.
6.2. Remove engine carrier with intermediate flange and holder for rear silencer.





Engine carrier with holder for rear silencer (turbo)

7. Remove intake air lines -1-.
7.1. Cylinder bank 1-3:
7.1.1. Remove hose connections on the ambient air valve -2 and 3- and unclip the hose -arrow-.
7.1.2. Unscrew two external Torx screws (E10, M6 x 30) on the turbocharger and remove the cover and the intake air line.





Intake air line on cylinder bank 1-3

7.2. Cylinder bank 4-6:
7.2.1. Disconnect positive crankcase ventilation line -4- , remove hose connections on the ambient air valve -2 and 3- and unclip the hose -left arrow-.
7.2.2. Unscrew two external Torx screws (E10, M6 x 20) on the turbocharger and remove the intake air line.





Intake air line on cylinder bank 4-6

8. Remove secondary-air pump -1-.
-> 266519 Removing and installing secondary-air pump - Turbo.
8.1. Pull off hose -2- and disconnect cable plug.
8.2. Unscrew two M6 external Torx screws (E10) and remove the pump.





Secondary-air pump on cylinder bank 1-3

9. Loosen three external Torx screws (E12, M8 x 12) -2- on the hydraulic pump pulley -1- (do not unscrew fully).





Hydraulic pump pulley

10. Remove the drive belt.
-> 137819 Removing and installing drive belt - Turbo Service and Repair.
10.1. Unscrew screws for hydraulic pump pulley and remove the pulley.
11. Remove the generator.
-> 272219 Removing and installing generator Service and Repair.
11.1. Unplug electric plug connection -1- and lift off the rubber cover -2- with a screwdriver -arrow-.





Electric connections on generator

11.2. Loosen the B+ line by unscrewing one M8 hexagon nut (a/f 13) -1-.





B+ line on generator

12. Completely remove the intake-air distributor -1-.
-> 244619 Removing and installing intake-air distributor - Turbo Service and Repair.
12.1. Remove connections on the centre part.
12.2. Unscrew one external Torx screw (E10, M6 x 16) used to secure the cable duct.
12.3. Unscrew two external Torx screws (E10, M6 x 12) at the oil filler tube.
12.4. Disconnect cable plug at the intake manifold pressure sensor and engine compartment temperature sensor.
12.5. Unscrew six external Torx screws (E10, M6 x 35) on each intake-air distributor and remove the intake-air distributor by lifting up cylinder bank 4-6 first -arrow-.





Lifting off intake-air distributor completely

13. Remove oil return lines and exhaust temperature sensor.
-> 217819 Removing and installing oil return line for turbocharger.
-> 216420 Removing and installing exhaust temperature sensors.
13.1. Remove oil return line -1- and exhaust temperature sensor -4- on turbocharger 1-3.





Exhaust temperature sensor, bank 1-3

13.2. Remove exhaust temperature sensor -1- on turbocharger 4-6.





Exhaust temperature sensor, cylinder bank 4-6

13.3. Remove oil return line.





Oil return line on turbocharger 4-6

13.4. Expose line -1- for exhaust temperature sensor 4-6 -arrows-.





Line routing for exhaust temperature sensor 4-6 at bottom of engine

13.5. Remove oil return lines -1- at the oil pan.





Oil return line at the oil pan

14. Loosen fastening points securing coolant and oil lines to the turbocharger.
14.1. Coolant lines -1- and oil line -3- on cylinder bank 1-3: Open spring band clamps -2- and unscrew two M6 external Torx screws (E10) -4 and 5-.





Coolant and oil lines on cylinder bank 1-3

14.2. Remove oil pressure line from the cylinder head. Unscrew one external Torx screw (E10, M6 x 12).
14.3. Coolant lines and oil line on cylinder bank 4-6: Unscrew three M6 external Torx screws (E10) -1 to 3-.





Coolant lines and oil line on cylinder bank 4-6





14.4. Loosen the oil pressure line -1- at the holder by unscrewing the external Torx screw (E10, M6 x 12) -2-.





Holder for oil pressure line on cylinder bank 4-6

14.5. Replace O-rings on oil pressure lines.
15. Remove turbocharger with wire assembly.
-> 213019 Removing and installing turbocharger.
16. Remove heat shields -2-. Unscrew two external Torx screws (E10, M6 x 12) -3-.





Heat shield (view of cylinder bank 1-3)

17. Remove exhaust manifold.
-> 261019 Removing and installing exhaust manifold - Turbo Service and Repair.
18. Drain engine oil.
-> 170155 Changing engine oil and oil filter - Turbo Removal and Replacement.
18.1. Unscrew drain plug and collect emerging oil.
18.2. Then screw in drain plug with a new sealing ring and tighten to the specified torque.
=> Tightening torque: 50 Nm (37 ftlb.)
19. Remove oil filler neck -1-.
-> 171519 Removing and installing oil filler neck - Turbo.
19.1. Unscrew two external Torx screws (E10, M6 x 20) -2- and pull the connection piece out of the crankcase.
19.2. Close off opening with adhesive tape or a stopper.
19.3. Replace O-ring.





Oil filler neck

20. Unplug cable plugs in the cylinder head cover area, disconnect ground straps for ignition coils and unclip cable duct.
20.1. Cylinder bank 1-3:





Cable plugs and electric lines on cylinder bank 1-3





20.2. Cylinder bank 4-6:





Cable plugs and electric lines on cylinder bank 4-6





21. Remove holder for turbocharger, pull off bar ignition modules and disconnect coolant pipe.
21.1. Unscrew two external Torx screws (E12, M8 x 35) -2- and remove the holder -1-.
21.2. Pull off bar ignition modules -3-.





Holder for turbocharger and bar ignition modules

22. Disconnect B+ line -1- and control line for solenoid switch (terminal 50) -2- at the starter.
-> 276019 Removing and installing starter Service and Repair.





Screwing off fastening nuts for cable shoe on the starter

23. Remove positive crankcase ventilation line -1- (air-conditioning compressor remains in the vehicle when you remove the engine).
23.1. Open rapid-action couplings by pressing the locking ring -3- and unclip line from the holder -arrow-.
23.2. Replace O-rings on the connection point to the bracket for the oil/water heat exchanger.





Positive crankcase ventilation line

24. Remove hydraulic pump -1- together with the pressure line -2- and return line -3-.
-> 489819 Removing and installing hydraulic pump Service and Repair.





Hydraulic pump and lines

25. Remove housing cover for coolant regulator -1- and coolant intake tube -5- (from the coolant reservoir).
25.1. Unscrew one external Torx screw (E10) M6 x 40 -2- , three M6 x 50 screws -3- and take off the cover and thermostat.
25.2. Unscrew two external Torx screws (E10, M6 x 12) -4- and pull off the intake tube. Replace O-rings.





Intake tube and coolant regulator housing

26. Disconnect vent line -1- , unclip B+ line -2- and remove the oil separator -3-.
26.1. Unscrew two external Torx screws (E10, M6 x 25) -4- and pull off the oil separator. Replace O-rings.





Oil separator with B+ line

27. Remove secondary-air lines.





Secondary-air lines

28. Remove electric control valve -1- and vacuum lines -3- on the flywheel side.
28.1. Release cable plug on control valve -2- and pull it off.





Electric control valve with vacuum lines

29. Expose oil-level sender cable -1- and vacuum line -2-.
29.1. Expose vacuum line and cable and loosen vacuum line holder -3-.
29.2. Release and pull off cable plug -4- for oil-level sender at the oil pan.





Vacuum line for brake booster and oil-level sender cable

30. Unplug several cable plugs at the engine, unclip all cable holders and unscrew two external Torx screws (E12, M8 x 16) on the cable duct.
-> 975219 Removing and installing wire harness for engine.
- Solenoid hydraulic valve for camshaft control (top of cylinder head)
- Fuel pressure sensor on fuel collection pipe, cylinder bank 4-6
- Oil pressure and temperature sensor on bracket for oil/water heat exchanger
- Fuel injectors
- Knock sensors
- Flow control valve on high-pressure pump
- Coolant temperature sensor on unit carrier
- Pressure-regulating valve
- Coolant run-on pump

30.1. Remove engine wire harness.
31. Remove coolant pipe with coolant hose and connection piece (Henn coupling).
31.1. To do this, unscrew three external Torx screws (E12, M8 x 70) -2- on the unit carrier at the right.





Unit carrier

31.2. Unscrew two external Torx screws (E10, M6 x 12) -2- and remove the coolant pipe and connection piece -1-.





Coolant pipe with hose and connection piece

32. Remove coolant distributor -1- and coolant hoses.
32.1. Open two spring band clamps and pull off coolant hoses. Unscrew two external Torx screws (E10, M6 x 25).





Coolant distributor

32.2. Pull the coolant distributor -1- up out of the coolant pipes -2-.





Coolant distributor and connecting pipes